Vacuum cleaner having two expanded polypropylene shells

ABSTRACT

The invention concerns a vacuum cleaner ( 100 ) comprising a lower body ( 200 ) and an upper body ( 400 ) enclosing in particular a motor fan unit and a waste separating device. The invention is characterized in that: the lower body ( 200 ) and the upper body ( 400 ) are made of expanded polypropylene, at least one so-called upper rigid part ( 190 ) is supported on the upper body ( 400 ), or is secured to the upper body, at least one so-called lower rigid part ( 152, 162 ) is supported on the lower body ( 200 ), or is secured to the lower body, at least one rigid linking element ( 150, 160, 194, 520 ) is mechanically linked to at least one upper part ( 190 ) and to one lower part ( 152, 162 ) passing through the upper body ( 400 ) and the lower body ( 200 ) so as to maintain by compression the upper ( 400 ) and lower ( 200 ) bodies.

The invention relates to the field of electrical vacuum cleaners and more particularly the structure of a vacuum cleaner.

Historically, appliances, including vacuum cleaners, have incorporated, with various benefits, plastics which became available, as the development of technological implementation of polymers and their various performances advanced, each being specifically chosen for a particular function: resistance to temperature, stiffness or flexibility, sound damping, aesthetics, etc. . . . Today, there are more than a half-dozen different plastics in the body of a vacuum cleaner: ABS, nylon, polyethylene, polypropylene, PVC, rubber, etc.

Several components are manufactured separately and attached to form the body of the appliance as well as the cover for the housing of the dust bag, filter element supports, etc. . . .

The plastics used in vacuum cleaners are as thin as possible so as to limit the weight of the appliance and reduce the effort needed for handling the vacuum cleaner during its use, this handling being an important cause of fatigue, for example when going from one story to another or when stairs are to be cleaned.

A first problem encountered during the manufacture of a vacuum cleaner is therefore reducing the weight of the appliance, this problem being a permanent concern for manufacturers of vacuum cleaners.

The weight reduction sought is reflected in the thinning of the shell and of the body, which is counter to the sturdiness of the appliance. Indeed, the weight of plastic used in the manufacture of a vacuum cleaner quickly reaches a limit set by the sturdiness of the whole.

A second problem is therefore to maintain the sturdiness of the hull and body while sharply reducing the weight of the plastic used and that of the vacuum cleaner.

The passage of the vacuum cleaner through the house is usually not a task regarded as very pleasant and as a result, the appliance is used carelessly. It thus frequently happens that the appliance strikes furniture, walls or other objects placed in the room to be cleaned. On this occasion, given the rigidity of the frame of the vacuum, the party struck is often damaged.

A third problem for manufacturers of vacuum cleaners is therefore to combine good mechanical characteristics of the housing with a possible shock absorption to limit the effects of careless manipulation. A solution to this problem can be found with rubber bands surrounding, like a belt, the body of the appliance. Such a solution generates a significant additional cost.

Moreover, in the current situation of waste recycling of all kinds, including household appliances at the end of life, all manufacturers concerned about the environment and taking note of their approach towards sustainable development are seeking ways to minimize the weight of the materials to be recycled and use as much as possible materials that can be recovered easily. It is indeed known that the environmental impact of a vacuum cleaner comes, in large part, from its composition.

A fourth problem that is presented is therefore to produce a vacuum cleaner in which materials can be easily, and if possible fully, recycled.

The invention thus has for its object to resolve these principal difficulties, i.e., aims to achieve a vacuum cleaner of low weight, of increased sturdiness, being able to absorb shocks and having a high “recyclability” at the end of its life, while assembly of the various elements that constitute it being simple.

According to the invention, the vacuum cleaner has a lower body and an upper body enclosing particularly a motor-ventilator and a device for separation of waste, characterized in that:

-   -   the lower body and upper body are made of expanded         polypropylene,     -   at least one rigid part called upper provides support on the         upper body, or is integrated into the upper body,     -   at least one rigid part called lower provides support under the         lower body, or is integrated into the lower body,     -   at least one rigid connecting element is mechanically connected         to at least one upper piece and one lower piece by extending         across the upper body and lower body,         in order to effect a holding by compression of the upper and         lower bodies.

By body of the appliance, it is necessary to understand the visible exterior of the appliance, which can take various names: casing, shell, housing . . . .

The expanded polypropylene (EPP) is composed of beads that are molded into an object with a press in the presence of steam. Mainly used as shock absorbing material, including recently in the automobile (shock absorber), EPP has many qualities: able to withstand temperature up to 110° C., excellent stability, lightness, resistance to shocks, ability to be recycled, etc. . . . which makes it attractive. However, its low mechanical strength only makes it for the moment a complementary material in producing sub-assemblies.

The present invention ventures thus to provide constituent parts of the body of the vacuum cleaner, requiring a certain rigidity, sturdiness and mechanical strength, made of EPP, which was not envisioned, originally, for that purpose.

The production of the lower and upper bodies of EPP gives them great flexibility, in addition to the benefits arising from its intrinsic properties described above.

This aspect is used in the present invention. Indeed, by the relatively large deformation of EPP which, notably, does not alter its mechanical properties, this invention aims particularly at simplifying the mode of assembly of an upper body on a lower body by compressing the upper body on the lower body by rigid parts providing support under the lower body, or integrated into the lower body and on the upper body, or integrated into the upper body, which allows a simple implementation while allowing control and adjustment of the deformation of the two bodies in order to achieve a seal between the upper body and the lower body, without a specific joint.

Advantageously, in order to simplify the number of elements, at least one connecting element originates from one of the rigid parts.

However, using a preferred implementation of the invention, at least one connecting element is composed of two rods originating respectively from one rigid part supported on the upper body and one rigid part providing support under the lower body, said rods being mechanically connected to one another, either by screws or by clips, or by any other means known per se.

Another purpose of this invention is to favor polypropylene in the choice of plastic. Another object of the invention is to use, at more than 90%, a single type of plastic, polypropylene, in the entire body of the vacuum cleaner. The polypropylene can be used in two forms: classic polypropylene (PP), which has the properties conventional plastics and expanded polypropylene (EPP).

Thus, preferably, the connecting element or elements, as well as the rigid parts are made of non-expanded polypropylene (PP).

Advantageously, to distribute the force on the upper part and minimize the risk of escape of air, the bearing of the rigid upper part on the upper body forms a plate covering at least 20% of the upper surface of said body.

On the other hand, always for the sake of simplification and rationalization of components of the appliance, the support of the lower part under the lower body has displacement elements of the vacuum cleaner. This simplification generates cost reductions for assembly and components.

Other features and advantages of the invention will be given by the description that will follow, in light of the annexed figures which only constitute an example of a non-limiting realization, where the FIGS. 1 to 6 present a first embodiment of the invention, while the FIGS. 7 to 13 present a second embodiment of the invention.

FIG. 1 is a perspective view of a vacuum cleaner according to a first mode of implementation of the present invention.

FIG. 2 is a perspective view of the upper and lower bodies of the vacuum cleaner.

FIG. 3 is an exploded view in perspective of the upper and lower bodies of the vacuum cleaner.

FIG. 4 is a top view of the lower and upper bodies, intentionally separated from one another.

FIG. 5 is an exploded bottom view of the vacuum cleaner.

FIG. 6 is an exploded view of certain parts of the vacuum cleaner.

FIG. 7 is a perspective view of a vacuum cleaner assembled according to a second mode of implementation of the present invention.

FIG. 8 is an exploded view of the various major parts of the vacuum cleaner.

FIG. 9 is a bottom perspective view of certain parts of the vacuum cleaner.

FIG. 10 is a top view of the upper body of the vacuum cleaner.

FIG. 11 is an exploded perspective view of certain parts of the vacuum cleaner.

FIGS. 12 and 13 are views from two perspectives of certain assembled parts of the vacuum cleaner.

According to a first mode of implementation of the invention, as illustrated in FIGS. 1 to 6, a vacuum cleaner 1 is conventionally made up of a vacuum cleaner body inside which is housed a motor-ventilator (not shown) generating a suction force and a circulation of air from the end of a pipe coming to be connected, by a tube 4, in an opening 30 arranged on the body of the vacuum cleaner, to the evacuation toward the rear of the appliance through 34 slots. In this process of removing dust, the air flow passes through a housing 24 containing the filter bag for collecting dust (not shown).

The body of the vacuum cleaner is composed of two main parts manufactured separately and then assembled on one another:

-   -   a lower body 20 with a housing 26 for the motor-ventilator, a         space 24 provided for receiving the filter bag, a housing 28 for         an electric cord reel 13, fittings for maneuvering elements such         as wheels or casters 10. Lower body 20 also has an insert 5 for         connection of tube 4 permitting attachment of the suction         nozzle. A handle 22 is also formed in the lower body.     -   an upper body 40 on which can be fitted control elements, such         as an on-off button 8 connected with a switch 9, and a button 6         for retracting the electric cable. The upper body also has an         opening 46 for reception of an electronic control card. As is         clearly visible in FIGS. 3 and 4, the upper body includes a         housing 42 for the motor-ventilator, extending toward the lower         body by walls 44 for partitioning off the motor-ventilator. A         front portion 48 of the upper body provides, with the lower         body, housing 24 for the device for separation of waste. This         fitting together of the two bodies in this part lying         horizontally essentially allows correct positioning of the two         bodies on one another, and assures a good support of the upper         body on the lower body.

According to the invention the constituent material of the body of the vacuum cleaner, whether of the lower body 20, the upper body 40, is expanded polypropylene (EPP).

The low mechanical strength of EPP has however necessitated a considerable increase in the thickness of the walls in order to present a sufficient sturdiness. However, and surprisingly, even if the volume of material needed then leads to a vacuum cleaner that is slightly more voluminous than normal, the mass of plastic can be significantly reduced and the weight of the final vacuum cleaner may be cut in half.

The amount of weaker material is also advantageous from an economic viewpoint, since the vacuum cleaner is less costly to manufacture.

The great flexibility of EPP allows improved absorption of shocks in relation to other plastics traditionally used for manufacturing vacuum cleaners. With this great flexibility is associated, depending on the degree of expansion, an elastic memory of the material, which also has significant advantages in terms of assembly of different attachments fitted on the body of the appliance. Indeed, it is thus possible to articulate for example different lids without hinges and to lock them simply by deforming the material. This curious feature also helps to fix inserts, by nesting, without difficulty.

It suffices to “force” the material to become deformed to lock or fix an insert, the material resuming its shape after deformation to hold the assembly.

The different parts are thus assembled in a manner that forms a good seal, which has an important advantage for the effectiveness of the suction by the motor-ventilator and the efficiency of the various filter elements. The flexibility of EPP allows locking of many parts, inserts or electrical cords in absorbent material without the possibility of movement, especially over time, particularly as a result of vibrations of the motor-ventilator.

This good sealing by the material itself permits avoiding, or at least significantly limiting, the use of joints, particularly at the level of the suction channel, which is economical in terms of quantity of material and assembly time of the vacuum cleaner.

The vacuum cleaner thus has advantageously at least one assembly between a part made of expanded polypropylene and another part, produced by deformation of the expanded polypropylene part. This deformation can permit, as well as the mechanical strength of the parts, to form a sealing joint.

According to the proposed example, a lid 60 made of expanded polypropylene is disposed on the lower and upper bodies. This lid permits the closure of the dust bag housing. Incidentally, this lid may receive, in its thickness, various vacuuming accessories such as a small brush, suction nozzle, etc

According to the invention, the holding of the upper body on the lower body is assured by connecting elements constituted by rods 12 taking support under lower body 20 and coming to be connected with a rigid part 80 disposed on upper body 40. Such an arrangement is particularly illustrated in FIGS. 5 and 6.

The supports for rods 12 under lower body 20 are made by rigid parts 14 for rods located at the rear, preferentially associated with the rollers 10 of the vacuum cleaner. As concerns the rod 12 located at the front, it is associated with the center roller through a platform 11 permitting recentering of the wheel relative to the whole of the vacuum cleaner, while providing a consistent support surface.

The rods penetrate into openings 32 of lower body 20, as is clearly visible in FIG. 4 or 5.

The assembly strictly speaking of the upper body on the lower body consists, according to the example shown, in screwing the rods 12 into corresponding tubes 82 originating from rigid part 80, these tubes advantageously passing through an upper body part 40 in three openings 50 shown in FIGS. 3 and 4.

Screwing thus permits compression, through the intermediary of rigid part 80, of the upper body on the lower body, the relatively large deformation of the EPP, as previously described, permitting sealing to be achieved between the lower and upper bodies, without a specific joint.

Rigid part 80 may have very different forms and conformations, ranging from a piece covering substantially the entire surface of the upper body, as shown, to a more indented, or cut-out, part, promoting compression only around tubes 82. It is even possible to envisage the provision of several independent pieces.

Similarly, and inversely, the bearing surface under the lower body can be provided by a more or less extended plate, like rigid part 80. It is then possible to have a rigid part under the lower body and more localized support points on the upper body.

The version as illustrated offers the advantage of being able to realize other functions by the rigid part arranged on the upper body. Thus, the rigid part presents a housing 86 for a sponge 84 to filter the air exiting from the motor-ventilator, as well as the sites for control buttons 6 and 8.

Moreover, this invention is not limited to a connection between the upper body and the lower body at three points, other architectures being able to be considered as part of the invention.

Other methods of assembly and configuration can be envisioned without leaving the framework of the invention. In particular rods 12, or tubes 82, can extend completely across the lower and upper bodies, assembly then being achieved by a nut or equivalent device, the principle being to achieve a compression of the lower and upper bodies.

Signal lights, control and maneuvering elements 6, 8, as well as rigid part 80, tubes 12, parts 14 and rollers 10 will be preferentially made of non-expanded polypropylene.

According to a second example of carrying out the invention, shown in FIGS. 7 to 13, the vacuum cleaner 100 according to the invention is constituted by a vacuum cleaner body composed of three main parts manufactured separately and then assembled afterward:

-   -   a small lower body 200 having:         -   a housing 220 for the lower part of the motor-ventilator,         -   a space 222 for the rear maneuvering elements such as wheels             or rollers 153, visible in FIGS. 12 and 13,         -   an air outlet 260 of the vacuum cleaner,         -   a housing 230 for the lower part of an electric cord             retractor 110,     -   a substantial upper body 400 comprising:         -   a space 402 arranged for receiving a filtering dust bag,         -   a housing 404 for the upper part of electric cord retractor             110,         -   a space 406 for the front maneuvering elements (roller 155)             of the vacuum cleaner,         -   a recess 408 for housing the upper part of the             motor-ventilator, conjointly with housing 220 of lower body             200,         -   un insert 405 allowing the connection of suction pipes, this             insert cooperating with a bag support 407 disposed in space             402.     -   a rear body 500 having a large handle 502 for carrying the         vacuum cleaner.

Just like the first example of implementation of the invention, the constituent material of the vacuum cleaner, whether of the 400 upper body, the lower body 200, as well as the rear body 500, is expanded polypropylene (EPP).

However, in order to reinforce the resistance to shocks of handle 502, rear body 500 includes a rigid frame 510 of non-expanded PP around which is overmolded a covering 513 of expanded polypropylene, to be able to mechanically resist a possible severe impact on the handle. A portion of the frame thus forms a reinforcement for the carrying handle of the vacuum cleaner.

Such a frame 510 is clearly visible in FIG. 11, which shows the rear body 500 in an exploded view where frame 510 is artificially separated from covering 513. Frame 510 presents notably a handle reinforcement 512 terminated by a planar rib 514 in an arc of a circle, allowing a better attachment and a better strengthening of the EPP.

According to this second example of implementation, the vacuum cleaner also includes a lid 180 permitting closure of the bag housing, made of expanded polypropylene and disposed on the upper body. The mechanical holding of the lid on upper body 400 of the vacuum cleaner is obtained by nesting, in deforming the material, as previously explained.

According to the suggested example, holding of the upper and lower bodies to one another is assured by rods 150, 160 taking support under lower body 200. Rods 150 come to engage with rear part 500, while rod 160 is connected to a rigid part 190 disposed on upper body 400.

The supports for rods 150 and 160 under lower body 200 are preferentially associated with the rollers of the vacuum cleaner, as is clearly visible on the FIGS. 12 and 13. Regarding the center roller 155, the latter is associated with a platform 162 permitting the roller to be recentered relative to the whole of the vacuum cleaner, while allowing the tightening force to be distributed.

Rear rollers 153 are associated with a rigid part 152 that participates in the compression of the lower body on the upper body, said part carrying the two rear rods 150.

The assembly, strictly speaking, of the upper body on the lower body consists, according to the example shown, in screwing the rods 150 and 160 in corresponding tubes originating from parts 190 and 500, the tubes and/or the rods advantageously extending across a portion of upper body 400.

FIGS. 8, 12 and 13 show particularly such a tube 194 originating from part 190, this tube receiving the rod 160, which extends across lower body 200 through opening 224. Tube 194 extends across, for its part, upper body 400 through the opening 410, as illustrated in FIG. 10.

According to the invention, frame 510 of the rear body is mechanically linked to at least one rigid part in support under the lower body, through the intermediary if at least one connection element. Thus, rods 150 traverse lower body 200 through openings 226 and are in mechanical engagement with complementary tubes 520 originating from frame 510 of rear body 500, and partially traversing upper body 400 through openings 412.

FIGS. 12 and 13 illustrate different rigid parts allowing compression of the lower and upper bodies.

As is particularly visible in FIG. 13, rear body 500 bears on plate 190, thus indirectly on upper body 400.

Moreover, as shown in FIG. 8, the two rods 150 are tilted relative to rod 160, in order to promote compression of the rear part on the lower and upper bodies.

Like the first example of implementation, rigid part 190 may present very different forms and conformations, ranging from a part covering substantially the entire width of the upper body, as shown, at the rear of the dust bag compartment, to a more recessed part. It is even possible to envisage the implementation of several independent parts.

Similarly, and inversely, the bearing surface under the lower body can be assured by a more or less extended plate, like the rigid part 162. It is then possible to arrange a rigid part under the lower body and more localized support points on the upper body.

Rigid part 190 also has places for on/off control button 196, as well as button 198 for retracting the electric cord on retractor 100.

Rigid part 190 also has a housing 192 for a casing 195 containing a pleated HEPA type filter, to filter air from the dust bag before entering the motor-ventilator.

Signal lights, control and maneuvering elements 196, 198, as well as rigid part 190, tubes 194, 150, 160 as well as parts associated therewith, like the rollers, will be preferentially made of non-expanded polypropylene.

The motor-ventilator, not shown, will be advantageously disposed within a casing 120, having a stack, or chimney, 124 inside which is disposed a circuit card to control the motor-ventilator. The chimney is an extension of a part 122 constituting the cover of casing 120 for the motor-ventilator. This casing is advantageously constituted by rigid parts made of non-expanded polypropylene.

Casing 120 also includes a substantially cylindrical fairing 130, surrounding the motor-ventilator and on which is fixed the cover 122 by a bayonet-type assembly.

Preferably, the fairing has a multitude of openings 132 for the exhausting of air, these openings, cylindrical in form, have a diameter of about 2.5 mm.

In order to further reduce noise generated by the motor-ventilator, a sponge 134 is disposed in front of openings 132, so that the air exiting fairing 130 passes through such a sponge before reaching the exit 260 of lower body 200.

Preferably, the fairing of the motor-ventilator is made of non-expanded polypropylene to limit the diversity of materials used.

As concerns expanded polypropylene, it will be used with degrees of expansion defined by the quantity of material (polypropylene) per liter. Use will preferably be made of contents between 40 g and 80 g of material per liter.

Moreover, in order to facilitate recycling of the polypropylene used, preference will be given to the use of homopolymers.

Although the examples of implementation show rigid upper and lower parts distinct from the upper and lower bodies, it may be envisioned in the context of the invention, to insert said parts in the respective bodies. Thus, one of the rigid upper parts, participating in supporting the upper and lower bodies, can be integrated into the upper body, provided that the part is located in the upper part of said body so that compression is achieved over a sufficient thickness of the upper body.

Similarly, one of the lower parts participating in supporting the upper and lower bodies may also be integrated into the lower body, preferably in its lower part, to keep a sufficient thickness of the lower body to perform the compression and support of the different bodies.

The integration of the rigid parts into the upper and lower bodies helps reduce the risk of damage to furniture and objects in the room being cleaned, since these rigid parts are covered and protected by a casing of EPP. 

1. Vacuum cleaner (1, 100) with a lower body (20, 200) and an upper body (40, 400) enclosing particularly a motor-ventilator and a device for separating waste, characterized in that: the lower body (20, 200) and the upper body (40, 400) are made of expanded polypropylene, at least one upper rigid part (80, 190, 510) is supported on the upper body (40, 400), or is integrated into the upper body, at least one lower rigid part (11, 14, 152, 162) is supported under the lower body (20, 200), or is integrated into the lower body, at least one rigid connecting element (12, 82, 150, 160, 194, 520) is mechanically connected to at least one upper part (80, 190, 510) and a lower part (11, 14, 152, 162) by passing across the upper body (40, 400) and the lower body (20, 200), in order to effect a holding by compression of the upper (40, 400) and lower (20, 200) bodies.
 2. Vacuum cleaner (1, 100) according to claim 1, characterized in that at least one connecting element (12, 82, 150, 160, 194, 520) originates from one of the rigid parts (11, 14, 80, 152, 162, 190, 510).
 3. Vacuum cleaner (1, 100) according to claim 1, characterized in that at least one connecting element is composed of two rods (12, 82, 150, 160, 194, 520) originating respectively from a rigid part (80, 190, 510) supported on the upper body (40, 400) and a rigid part (11, 14, 152, 162) supported under the lower body (20, 200), said rods (12, 82, 150, 160, 194, 520) being mechanically connected to one another.
 4. Vacuum cleaner (1, 100) according to claim 1, characterized in that the mechanical connection between one of the upper parts (80, 190, 510) and one of the lower parts (11, 14, 152, 162) by the connecting element (12, 82, 150, 160, 194, 520) is of the screw type.
 5. Vacuum cleaner (1, 100) according to claim 1, characterized in that that the mechanical connection between one of the upper parts (80, 190, 510) and one of the lower parts (11, 14, 152, 162) by the connecting element (12, 82, 150, 160, 194, 520) is clip type.
 6. Vacuum cleaner (1, 100) according to claim 1, characterized in that that the connecting element (12, 82, 150, 160, 194, 520) and the rigid parts (11, 14, 80, 152, 162, 190, 510) are made of non-expanded polypropylene.
 7. Vacuum cleaner (1, 100) according to claim 1, characterized in that that the support for the upper rigid part (80, 190) on the upper body (40, 400) forms a plate (80, 190) covering the least 20% of the upper surface of said body.
 8. Vacuum cleaner (1, 100) according to claim 1, characterized in that that the support for the lower part (11, 14, 152, 162) under the lower body (20, 200) includes elements (10, 153, 155) for moving the vacuum cleaner (1, 100).
 9. Vacuum cleaner (100) according to claim 1, characterized in that it has a rear body (500) comprising a rigid frame (510) around which is overmolded a covering (513) of expanded polypropylene.
 10. Vacuum cleaner (100) according to the claim 9, characterized in that a portion of the frame (510) forms a reinforcement for a handle (512) for transport of the vacuum cleaner (100).
 11. Vacuum cleaner (100) according to claim 9, characterized in that the rear body (500) bears on the upper body (400).
 12. Vacuum cleaner (100) according to claim 11, characterized in that the frame (512) of the rear body is mechanically connected to at least one rigid part (152) bearing under the lower body (200), through at least one connecting element (150).
 13. Vacuum cleaner (100) according to claim 9, characterized in that the frame (512) of the rear body (500) is made of non-expanded polypropylene.
 14. Vacuum cleaner (1, 100) according to claim 1, characterized in that it has a closing lid (60, 180) made of expanded polypropylene coming to be positioned on the upper body (40, 400) and/or on the lower body (20).
 15. Vacuum cleaner (1, 100) according to claim 14, characterized in that the expanded polypropylene and the non-expanded polypropylene used are homopolymers.
 16. Vacuum cleaner (1, 100) according to claim 1, characterized in that the expanded polypropylene has a content of between 40 g and 80 g of material per liter. 